U.S. patent application number 14/455650 was filed with the patent office on 2015-02-12 for article of footwear with extruded components.
The applicant listed for this patent is Reebok International Limited. Invention is credited to Mike ANDREWS, Paul DAVIS, Dustin SIMONE.
Application Number | 20150040428 14/455650 |
Document ID | / |
Family ID | 52447342 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150040428 |
Kind Code |
A1 |
DAVIS; Paul ; et
al. |
February 12, 2015 |
Article Of Footwear With Extruded Components
Abstract
The disclosed embodiments relate to portions of an article of
footwear formed from an extruded member. In certain embodiments, a
sole or portion of a sole can be formed from one or more extruded
members. In certain embodiments, the extruded member can be a
single, continuous piece of solid material. In certain embodiments,
a sole for an article of footwear can be fashioned from an extruded
member formed in a controlled geometric pattern. In certain
embodiments, the sole can include one or more layers.
Inventors: |
DAVIS; Paul; (Blackstone,
MA) ; ANDREWS; Mike; (East Falmouth, MA) ;
SIMONE; Dustin; (Boston, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Reebok International Limited |
London |
|
GB |
|
|
Family ID: |
52447342 |
Appl. No.: |
14/455650 |
Filed: |
August 8, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61864280 |
Aug 9, 2013 |
|
|
|
Current U.S.
Class: |
36/83 ; 12/146B;
36/25R; 36/30R |
Current CPC
Class: |
B29D 35/142 20130101;
B29C 64/106 20170801; B29C 64/118 20170801; A43B 23/0245 20130101;
A43B 13/12 20130101; A43B 13/181 20130101; A43B 13/023 20130101;
B33Y 80/00 20141201; A43B 13/14 20130101 |
Class at
Publication: |
36/83 ; 36/25.R;
36/30.R; 12/146.B |
International
Class: |
A43B 13/18 20060101
A43B013/18; A43B 13/14 20060101 A43B013/14 |
Claims
1. A sole for an article of footwear, the sole comprising: one or
more solid extruded members formed in a controlled geometric
pattern having one or more layers.
2. The sole of claim 1, comprising a single solid extruded member
forming a plurality of layers.
3. The sole of claim 1, wherein a first layer comprises a first
solid extruded member and a second layer comprises a second solid
extruded member.
4. The sole of claim 1, wherein a first layer runs in a transverse
direction of the sole and a second layer runs in a lengthwise
direction of the sole.
5. The sole of claim 1, wherein a first layer runs in a lengthwise
direction of the sole and a second layer runs in a transverse
direction of the sole.
6. The sole of claim 1, wherein a first layer and a third layer run
in a first direction and a second layer runs in a second
direction.
7. The sole of claim 1, wherein a rearfoot area of the sole
comprises more layers than a midfoot area and forefoot area of the
sole.
8. The sole of claim 1, wherein a rearfoot area of the sole
comprises a coiled shape.
9. The sole of claim 1, wherein at least one layer comprises a
pattern having one or more gaps between the one or more solid
extruded members.
10. The sole of claim 1, wherein at least one layer comprises a
pattern having a plurality of undulations.
11. The sole of claim 10, wherein each undulation contacts an
adjacent undulation.
12. The sole of claim 10, wherein the undulations run in a
transverse direction of the sole.
13. The sole of claim 10, wherein each undulation forms a loop.
14. The sole of claim 10, wherein the undulations extend from a
medial side to a lateral side of the sole.
15. The sole of claim 1, wherein a first portion of the solid
extruded member comprises a first thickness and a second portion of
the solid extruded member comprises a second thickness.
16. The sole of claim 1, wherein a first portion of the solid
extruded member comprises a first density and a second portion of
the solid extruded member comprises a second density.
17. The sole of claim 1, wherein a first portion of the solid
extruded member comprises a first material and a second portion of
the solid extruded member comprises a second material.
18. The sole of claim 1, wherein the solid extruded member
comprises thermoplastic.
19. The sole of claim 1, wherein the solid extruded member
comprises foam.
20. The sole of claim 1, wherein the solid extruded member
comprises a substantially circular cross-section.
21. The sole of claim 1, further comprising a support member.
22. The sole of claim 21, wherein the support member is located
between a first and second layer of the one or more solid extruded
members.
23. The sole of claim 21, wherein the support layer is located in a
rearfoot area of the sole.
24. The sole of claim 1, further comprising an insole attached to a
top surface of the one or more solid extruded members and an
outsole attached to a bottom surface of the one or more solid
extruded members.
25. The sole of claim 1, wherein the one or more solid extruded
members are extruded directly onto an upper surface of an
outsole.
26. A method of manufacturing a sole for an article of footwear,
the method comprising: extruding one or more solid elongated
members in a controlled geometric pattern.
27. The method of claim 26, wherein extruding one or more solid
elongated members comprises forming a plurality of layers.
28. The method of claim 26, wherein extruding one or more solid
elongated members comprises extruding a single, continuous
elongated member.
29. The method of claim 26, wherein the solid elongated member is
extruded directly onto an upper surface of an outsole.
30. An article of footwear, comprising: an upper; and a sole
attached to the upper, the sole comprising a single, continuous
piece of extruded material.
Description
BACKGROUND
[0001] 1. Field
[0002] The present disclosure relates to footwear. More
specifically, the present disclosure relates to embodiments of
footwear having a sole and/or upper portion described herein.
[0003] 2. Background
[0004] Individuals can be concerned with the amount of cushioning
an article of footwear provides, as well as the aesthetic appeal of
the article of footwear. This is true for articles of footwear worn
for non-performance activities, such as a leisurely stroll, and for
performance activities, such as running, because throughout the
course of an average day, the feet and legs of an individual are
subjected to substantial impact forces. When an article of footwear
contacts a surface, considerable forces may act on the article of
footwear and, correspondingly, the wearer's foot. The sole
functions, in part, to provide cushioning to the wearer's foot and
to protect it from these forces. To achieve adequate cushioning,
many footwear soles are thick and heavy. When sole size and/or
weight are reduced to achieve other performance goals, protection
of the wearer's foot is often compromised.
[0005] The human foot is a complex and remarkable piece of
machinery, capable of withstanding and dissipating many impact
forces. The natural padding of fat at the heel and forefoot, as
well as the flexibility of the arch, help to cushion the foot.
Although the human foot possesses natural cushioning and rebounding
characteristics, the foot alone is incapable of effectively
overcoming many of the forces encountered during every day
activity. Unless an individual is wearing footwear that provides
proper cushioning, support, and flexibility, the soreness and
fatigue associated with every day activity is more acute, and its
onset accelerated. The discomfort for the wearer that results may
diminish the incentive for further activity. Also, inadequate
cushioning, support, or flexibility in an article of footwear can
lead to injuries such as blisters; muscle, tendon and ligament
damage; and bone stress fractures. Improper footwear can also lead
to other ailments, including back pain.
BRIEF SUMMARY
[0006] The disclosed embodiments relate to portions of an article
of footwear formed from an extruded member. In certain embodiments,
a sole or portion of a sole can be formed from one or more extruded
members. In certain embodiments, the extruded member can be a
single, continuous piece of solid material. An extruded footwear
component, such as a sole, can have advantages over traditionally
formed components, such as injection molded components. For
example, an extruded sole can be customized without having to
machine a new, expensive mold. The use of extruded members can also
allow for the use of shapes and geometries that are difficult to
achieve using conventional molding techniques.
[0007] In certain embodiments, a sole for an article of footwear
can include an extruded member formed in a controlled geometric
pattern. In certain embodiments, the sole can include one or more
layers. In certain embodiments, each layer can have one or more
extruded members. In certain embodiments, the layers can be
non-woven layers. In certain embodiments, at least two layers can
be formed from the same extruded member.
[0008] In certain embodiments, a sole for an article of footwear
can be formed from one or more solid extruded members arranged in a
controlled geometric pattern having one or more layers. In certain
embodiments, a first layer can be formed from a first solid
extruded member and a second layer can be formed from a second
solid extruded member. In certain embodiments, a first layer can
run in a transverse direction of the sole and a second layer can
run in a lengthwise direction of the sole. In certain embodiments,
a first layer can run in a lengthwise direction of the sole and a
second layer can run in a transverse direction of the sole. In
certain embodiments, a first and third layer can run in a first
direction and a second layer can run in a second direction. In
certain embodiments, the first and second directions can be
generally perpendicular.
[0009] In certain embodiments, various areas of the sole can
include more layers of one or more extruded members than other
areas of the sole. For example, in certain embodiments, a heel or
rearfoot area of the sole can have more layers than a midfoot area
and/or forefoot area of the sole. In certain embodiments, a
rearfoot area of the sole can have a coiled shape, designed to
provide additional support and/or cushioning for a wearer's heel.
In certain embodiments, a midfoot area of the sole can have more
layers than a rearfoot area and/or forefoot area of the sole. In
certain embodiments, a forefoot area of the sole can have more
layers than a rearfoot area and/or midfoot area of the sole.
[0010] Each layer can be formed in a controlled pattern. In certain
embodiments, a layer can be planar such that the layer is the
thickness of a single extruded member. Multiple patterns can be
included in a single layer. A layer that includes multiple patterns
can have the same or different patterns within the layer, and one
layer can have the same or different pattern from another layer. In
certain embodiments, at least one layer can have a pattern with one
or more gaps between the one or more extruded members. In certain
embodiments, at least one layer can have a plurality of
undulations. In certain embodiments, each undulation can contact an
adjacent undulation. In certain embodiments, the undulations can
run in a transverse direction of the sole, or at an angle with
respect to the lengthwise direction of the sole. In certain
embodiments, each undulation can form a loop having an open space.
In certain embodiments, the loops can have a round, flat, or angled
end portion at the medial or lateral side of the sole. In certain
embodiments, the undulations can extend partially or entirely from
a medial side to a lateral side of the sole.
[0011] Various physical properties of the extruded member can be
manipulated, adjusted, altered, and/or modified. For example, in
certain embodiments, the width, length, shape, wall thickness,
color, density, elasticity, material, etc. of the extruded member
can vary along the extruded member or between a first and second
extruded member.
[0012] In certain embodiments, an article of footwear can include
an upper and a sole attached to the upper, where the sole is formed
from a single, continuous piece of extruded material or a plurality
of extruded members. The extruded member can be made of rubber,
foam (e.g., dispensed urethane foam), silicone, plastic including
thermoplastic (e.g., TPU, nylon, or polypropylene), or any other
suitable material. The cross-section of the extruded member can be
substantially circular, oval, rectangular, triangular, square, or
any other suitable shape or design (e.g., star-shaped).
[0013] In certain embodiments, the sole can include a support
member, for example a rigid support member, which can be made from
any suitable material (e.g., plastic, metal, composite, or a
combination of materials). In certain embodiments, the support
member can made of a cushioning material such as foam. In certain
embodiments, the support member can be located between a first and
second layer of the one or more extruded members. The support
member can be located along the entire sole or at any portion of
the sole, for example, in a rearfoot, midfoot, and/or forefoot area
of the sole.
[0014] In certain embodiments, the sole can be a midsole having an
insole attached to a top surface of the one or more extruded
members and an outsole attached to a bottom surface of the one or
more extruded members. In certain embodiments, the extruded member
can be extruded directly onto the insole and/or outsole. In certain
embodiments, an adhesive can be applied to the insole and/or
outsole before extruding the extruded member onto it.
[0015] Methods of manufacturing an article of footwear and a sole
for an article of footwear are also disclosed. In certain
embodiments, a method for manufacturing a sole for an article of
footwear can include extruding one or more elongated members in a
controlled geometric pattern. In certain embodiments, the method
can include extruding one or more solid elongated members to form a
plurality of layers. In certain embodiments, the method can include
extruding a single, continuous elongated member. In certain
embodiments, the method can include extruding the elongated member
directly onto an outsole.
[0016] In certain embodiments, a method for manufacturing a
customized sole for an article of footwear can include measuring a
physical characteristic of a foot (e.g., pressure data), sending
data of the characteristic to a computing device controlling an
extruder, and extruding one or more elongated members in a
controlled geometric pattern to form the sole based on the pressure
data. In certain embodiments, the method can include recording the
pressure data in the computing device. In certain embodiments, the
method can include analyzing the pressure data using the computing
device. In certain embodiments, the method can include designing a
pattern for a sole based on the pressure data.
[0017] In certain embodiments, one or more extruded members can be
extruded directly onto an upper portion of an article of footwear.
In certain embodiments, a sole portion can be extruded and an upper
can be attached thereto, for example, by stitching or an adhesive.
In certain embodiments, an upper or a portion of an upper can be
formed from one or more extruded members. In certain embodiments,
an article of footwear including a sole and an upper can be formed
from one or more extruded members as a single, unitary structure.
By way of example, in certain embodiments, one or more extruded
members can be extruded onto fabric to form an upper, a midsole,
quarter panels, heel counter, etc., and the fabric can be formed,
cut, or sewn to form an article of footwear.
[0018] Additional features and embodiments will be set forth in the
description that follows, and in part will be apparent from the
description, or may be learned by practice of the disclosed
embodiments. Both the foregoing general description and the
following detailed description are exemplary and explanatory and
are not meant to be limiting, and are intended to provide further
explanation of the embodiments as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying figures, which are incorporated herein,
form part of the specification and illustrate embodiments of the
present disclosure. Together with the description, the figures
further serve to explain the principles of and to enable a person
skilled in the relevant arts to make and use the disclosed
embodiments. These figures are intended to be illustrative, not
limiting. Although the disclosure is generally described in the
context of these embodiments, it should be understood that it is
not intended to limit the scope of the disclosure to these
particular embodiments. In the drawings, like reference numbers
indicate identical or functionally similar elements.
[0020] FIG. 1 illustrates a top view of a sole for an article of
footwear according to an embodiment presented herein.
[0021] FIG. 2 illustrates a bottom view of a sole for an article of
footwear according to an embodiment presented herein.
[0022] FIG. 3 illustrates a perspective view of a sole for an
article of footwear according to an embodiment presented
herein.
[0023] FIG. 4 illustrates a lateral side view of a sole for an
article of footwear according to an embodiment presented
herein.
[0024] FIG. 5 illustrates a forefoot area of a sole for an article
of footwear according to an embodiment presented herein.
[0025] FIG. 6 illustrates a partial enlarged view of a sole for an
article of footwear according to an embodiment presented
herein.
[0026] FIG. 7 illustrates a top perspective view of a rearfoot area
of a sole for an article of footwear according to an embodiment
presented herein.
[0027] FIG. 8 illustrates a bottom perspective view of a rearfoot
area of a sole for an article of footwear according to an
embodiment presented herein.
[0028] FIG. 9 illustrates a perspective view of a rearfoot area of
a sole for an article of footwear according to an embodiment
presented herein.
[0029] FIG. 10 illustrates a top view of a sole for an article of
footwear according to an embodiment presented herein.
[0030] FIG. 11 illustrates a side view of the sole of FIG. 10
according to an embodiment presented herein.
[0031] FIG. 12 illustrates a top view of a sole for an article of
footwear according to an embodiment presented herein.
[0032] FIG. 13 illustrates a top view of a sole for an article of
footwear according to an embodiment presented herein.
[0033] FIG. 14 illustrates a top view of a sole for an article of
footwear according to an embodiment presented herein.
[0034] FIG. 15 illustrates a perspective view of a sole for an
article of footwear according to an embodiment presented
herein.
[0035] FIG. 16 illustrates a side view of a sole for an article of
footwear according to an embodiment presented herein.
[0036] FIG. 17 illustrates a bottom view of a sole for an article
of footwear according to an embodiment presented herein.
[0037] FIG. 18 illustrates a front view of a bladder according to
an embodiment presented herein.
[0038] FIG. 19 illustrates a perspective view of a bladder
according to an embodiment presented herein.
[0039] FIG. 20 illustrates a rear view of a bladder according to an
embodiment presented herein.
[0040] FIG. 21 illustrates an article of footwear according to an
embodiment presented herein.
[0041] FIG. 22 illustrates and extruder for extruding a sole
according to an embodiment presented herein.
[0042] FIG. 23 illustrates a process for manufacturing a sole
according to an embodiment presented herein.
[0043] FIG. 24 illustrates components of a system for manufacturing
a sole according to an embodiment presented herein.
[0044] FIG. 25 illustrates a schematic representing movement of an
extruder according to an embodiment presented herein.
[0045] FIG. 26 illustrates an extrusion system according to an
embodiment presented herein.
[0046] FIG. 27 illustrates extrusion nozzles according to
embodiments presented herein.
[0047] FIG. 28 illustrates an extrusion and last system according
to an embodiment presented herein.
[0048] FIG. 29 illustrates a sole for an article of footwear
according to an embodiment presented herein.
[0049] FIG. 30 illustrates a sole for an article of footwear
according to an embodiment presented herein.
DETAILED DESCRIPTION
[0050] Embodiments of the present disclosure will now be described
in detail with reference to embodiments thereof as illustrated in
the accompanying drawings, in which like reference numerals are
used to indicate identical or functionally similar elements.
References to "one embodiment", "an embodiment", "some
embodiments", "in certain embodiments", etc., indicate that the
embodiment described may include a particular feature, structure,
or characteristic, but every embodiment may not necessarily include
the particular feature, structure, or characteristic. Moreover,
such phrases are not necessarily referring to the same embodiment.
Further, when a particular feature, structure, or characteristic is
described in connection with an embodiment, it is submitted that it
is within the knowledge of one skilled in the art to affect such
feature, structure, or characteristic in connection with other
embodiments whether or not explicitly described.
[0051] It is understood that the term "sole" can refer to an entire
sole for an article of footwear, or any portion of a sole for an
article of footwear. For example, "sole" can refer to an outsole,
midsole, insole, or any portion or combination thereof. "Sole" can
refer to a forefoot area, midfoot area, or rearfoot area of a sole,
or any portion or combination thereof.
[0052] Various aspects of the present invention, or any parts or
functions thereof, may be implemented using hardware, software,
firmware, non-transitory tangible computer readable or computer
usable storage media having instructions stored thereon, or a
combination thereof, and may be implemented in one or more computer
systems or other processing systems.
[0053] The following examples are illustrative, but not limiting,
of the present disclosure. Other suitable modifications and
adaptations of the variety of conditions and parameters normally
encountered in the field, and which would be apparent to those
skilled in the art, are within the spirit and scope of the
disclosure.
[0054] Embodiments of the present disclosure include a sole 100 for
an article of footwear 10 (see FIG. 21) having one or more extruded
members 200. Sole 100, including one or more extruded members 200,
can provide the desired ride and feel characteristics to the
wearer. In certain embodiments, sole 100 can minimize the weight of
an article of footwear; control the flexion, resilience, and
support of the article of footwear; and provide customized desired
cushioning and shape for an article of footwear.
[0055] FIG. 1 illustrates a top view of sole 100 for an article of
footwear 10, according to an embodiment. Similarly, FIG. 3
illustrates a perspective view of sole 100, according to an
embodiment. Sole 100 can include forefoot area 110, midfoot area
120, and rearfoot area 130. Sole 100 can include medial side 140,
lateral side 150, top surface 160, and bottom surface 170 (see
FIGS. 2 and 3).
[0056] In certain embodiments, sole 100 can be formed from one or
more extruded member 200. In certain embodiments, extruded member
200 can be a solid material. In certain embodiments, extruded
member 200 can be a hollow tube. In certain embodiments, extruded
member 200 can be a foam or cellular material, or any other
suitable material. In certain embodiments, extruded member 200 can
be a single, continuous piece of extruded material.
[0057] Extruded member 200 can be a porous or non-porous material.
For example, extruded member 200 can be made of rubber, foam (e.g.,
dispensed urethane foam), silicone, plastic, thermoplastic (e.g.,
polyurethane, nylon, or polypropylene), or any other suitable
material. In certain embodiments, extruded member 200 can be a
composite or blended material, for example, but not limited to,
rubber and cork, rubber and thermoplastic resin, microspheres added
to a resin, glass or carbon fibers added to a resin, and/or
nanoparticles. In certain embodiments, extruded member 200 can be
an impregnated material. In certain embodiments, extruded member
200 can have a coating, for example, a sealant coating. Extruded
member 200 can be a cured or uncured material or a reactive or
non-reactive material.
[0058] Various physical properties of extruded member 200 may be
varied to provide the desired characteristics of sole 100. Physical
properties of extruded member 200 include, but are not limited to,
thickness, color, density, material, shape, elasticity, etc. In
certain embodiments, physical properties can be changed from a
first layer to a second layer of extruded member 200. For example,
one layer can be white and another layer can be blue. Physical
properties can also be changed within a single layer. For example,
a layer of extruded member 200 can be red in forefoot area 110,
white in midfoot area 120, and blue in rearfoot area 130. Other
physical properties can be similarly altered within a layer or from
one layer to the next. For example, it may be beneficial for
extruded member 200 to have a higher density in rearfoot area 130
to absorb impact to a wearer's heel. In certain embodiments, a
bottom layer or layers of extruded member 200 can have a higher
density to form an outsole, while an upper layer or layers can have
a lower density to form a midsole.
[0059] In some embodiments, the thickness of extruded member 200
can be varied within a layer or from one layer to the next. In
certain embodiments, the thickness can be varied by changing the
extruder speed. For example, increasing the extruder speed can
decrease the thickness of extruded member 200, and vice versa. The
thickness of extruded member 200 can also be adjusted by increasing
or decreasing the aperture size of the extruder nozzle. In certain
embodiments, the extruder nozzle can be configured to change the
size of the aperture without stopping the extruder.
[0060] The shape of extruded member 200 can also be changed within
a layer or from one layer to the next, providing different
cross-sections of extruded member 200. For example, as shown in
FIG. 27, extruder nozzle 810 can have an aperture 812 that is round
or square. Aperture 812 can be any other shape. In certain
embodiments, the shape of extruded member 200 can be changed in
real time, without having to stop the machine and change out the
extruder nozzle 810. For example, extruder nozzle 810 can have
multiple apertures 812 of different shapes and sizes that can be
selectively opened or closed to change the shape or size of
extruded member 200. This can allow sole 100 to be made from a
single extruded member 200 having different cross-sections.
Changing the shape of extruded member 200 can impart desired
qualities, for example, a shape that provides improved cushioning,
stability, or flexibility for an area of sole 100.
[0061] In some embodiments, the size of the extruder nozzle
aperture 812 may be dynamically adjusted in real time during an
extrusion process based on data received from a sensor operatively
connected to the extruder. The data may include, but is not limited
to, temperature, viscosity, and/or density of the extrusion
material or substrate receiving the extrusion material, temperature
of extruder components, such as, for example, the nozzle and the
extrusion surface, and time. By way of example, referring to FIG.
24, sensor 700 can receive the data. In certain embodiments, the
sensor can send the data to computer 702. Computer 702 can have a
processor, memory, etc., and be configured to carry out
instructions from a tangible computer readable medium. Extruder 704
can operate based on instructions from computer 702.
[0062] In certain embodiments, extruded member 200 can be a
co-extruded member. That is, a first material can be encapsulated
within a second material. This can provide an aesthetically
pleasing material that encapsulates a functional material. In
certain embodiments, a soft, cushioning material can be
encapsulated within a stiff, durable material, or vice versa. In
one embodiment, a first material may be encapsulated with a
material having a lower hardness or stiffness. For example, where
one or more extruded members 200 are used to provide a footwear
upper, an extruded member 200 providing a collar portion of the
upper, which may require stiffness for support but also cushioning
to prevent irritation, may be co-extruded with first and second
materials.
[0063] Sole 100 can be formed by extruding extruded member 200 in a
controlled geometric pattern. In certain embodiments, the pattern
can be a non-woven pattern. In certain embodiments, the controlled
geometric pattern can be created using computer-aided design (CAD)
or other computer design software. In certain embodiments,
computerized numerical control (CNC) can be used to control an
extruder (e.g., a three-axis pneumatic extruder) in order to form a
precise (i.e., non-random) pattern for sole 100. Variables such as,
but not limited to, the size and shape of the dispensing orifice
(i.e., extrusion die), dispensing pressure, dispensing temperature,
dispensing viscosity, dispensing height, table axis and table speed
can be adjusted to create the desired pattern.
[0064] In certain embodiments, extruded member 200 can be formed
into a plurality of layers to create sole 100. For example,
extruded member 200 can be formed into first layer 202, second
layer 204, third layer 206, and fourth layer 208, as illustrated in
FIG. 4. In certain embodiments, the plurality of layers can be
formed from a single, continuous extruded member 200. In certain
embodiments, each layer can be a separate extruded member 200. In
certain embodiments, each layer can include more than one extruded
member 200. In certain embodiments, at least a portion of two
layers can be formed from the same extruded member 200. Each layer
can be positioned directly on top of a preceding layer, or layers
can be formed at an angle with respect to a preceding layer.
[0065] In one embodiment, certain areas of sole 100 can include one
or more additional layers of extruded member 200 relative to other
areas of sole 100. In some embodiments, this can provide additional
cushioning or support at targeted areas of sole 100 in order to
maximize comfort and performance of the article of footwear. For
example, rearfoot area 130 can have one or more additional layers
of extruded member 200 to absorb impact to the wearer's heel. In
certain embodiments, the additional layer or layers can be shaped
to form coil 220 in rearfoot area 130, as illustrated in FIG. 1.
Other shapes, including, for example, but not limited to, circles,
ovals, and spirals can be formed from extruded member 200 to
provide similar benefits as coil 220.
[0066] Other areas of sole 100 can include one or more additional
layers of extruded member 200. In certain embodiments, forefoot
area 110 can include one or more additional layers of extruded
member 200 to absorb impact at the ball of the foot. For example, a
spiral pattern can be formed where the ball of the foot would be
located, and/or under each individual toe. In certain embodiments,
one or more additional layers can be included in midfoot area 120
to provide support for the arch of the foot. In certain
embodiments, one or more additional layers can be located along all
or part of medial side 140 and/or lateral side 150 to provide
stability.
[0067] FIG. 2 illustrates a bottom view of sole 100 for an article
of footwear, according to an embodiment. Bottom surface 170 of
extruded member 200 can have the same or different geometric
pattern or design as top surface 160 shown in FIG. 1. In certain
embodiments, extruded member 200 can be formed to have a plurality
of undulations 210 extending in a generally transverse direction
across forefoot area 110, midfoot area 120, and/or rearfoot area
130. In certain embodiments, extruded member 200 can be formed to
run lengthwise from forefoot area 110 to rearfoot area 130, or at
an angle with respect to the lengthwise direction.
[0068] With reference to FIGS. 1 and 2, for example, in certain
embodiments, extruded member 200 can be disposed such that adjacent
portions run in opposite directions (i.e., "double back") along a
direction of sole 100 (e.g., a transverse direction), forming
undulations 210 that can extend from medial side 140 to lateral
side 150 of sole 100. In certain embodiments, undulations 210 can
extend only partially across sole 100 such that they do not extend
entirely from medial side 140 to lateral side 150.
[0069] As shown, for example, in FIG. 2, in certain embodiments,
each undulation 210 can form a loop 212 as it doubles back across
sole 100. In certain embodiments, loop 212 can contact an adjacent
loop 212 at one or more contact point 214. In certain embodiments,
undulations 210 can be spaced such that loops 212 do not contact an
adjacent loop 212 (see FIG. 10). In certain embodiments, each
undulation 210 can contact an adjacent undulation 210 along its
entire length such that no gaps are formed between the material of
extruded member 200 as it doubles back while spanning from medial
side 140 to lateral side 150 (or along the length of sole 100).
Undulations 210 can also run in the lengthwise direction, or at an
angle with respect to the lengthwise direction.
[0070] In certain embodiments, the size and/or shape of loops 212
can vary. For example, loops 212 can be smaller near a front
portion of forefoot area 110 and larger as they approach midfoot
area 120. In certain embodiment, loops 212 can have curved ends
along medial side 140 and lateral side 150. In certain embodiments,
loops 212 can have flat or angled ends along medial side 140 and
lateral side 150. Other shapes and designs for undulations 210 are
contemplated. For example, undulations 210 can be shaped like a
waveform (e.g., sinusoidal, sawtooth, square, triangle, etc.).
Undulations 210 can be uniform or non-uniform. In certain
embodiments, the general shape of undulations 210 can be consistent
along the length of sole 100, but the amplitude of undulations 210
can vary between medial side 140 and lateral side 150 and along
forefoot area 110, midfoot area 120, and rearfoot area 130 of sole
100. In certain embodiments, the shape of undulations 210 can
change along the length of sole 100.
[0071] Many other patterns, shapes, and designs for extruded member
200 are contemplated including those that are difficult to produce
using conventional molding techniques. For example, some
non-limiting patterns of extruded member 200 include zigzags,
swirls, spirals, lines, coils, circles, dots, cross-hatching,
beading, concentric shapes, letters, moire patterns, fractal
shapes, pillars, piles, blocks, balls, and/or logos. These patterns
can be uniform or non-uniform. In certain embodiments, adjacent
portions of extruded member 200 can contact each other such that
when extruded member 200 cools, extruded member 200 has the
appearance of a single, solid piece of material. In certain
embodiments, more than one pattern can be formed within a single
layer. For example, forefoot area 110 can have a cross-hatch
pattern, midfoot area 120 can have a zigzag pattern, and rearfoot
area 130 can have a spiral pattern.
[0072] FIG. 4 illustrates a lateral side view of sole 100,
according to an embodiment. As explained above, in certain
embodiments, extruded member 200 can have a plurality of layers.
For example, as shown in FIG. 4, extruded member 200 can have first
layer 202, second layer 204, third layer 206, and fourth layer 208.
In certain embodiments, each layer can be planar, such that the
layer is the thickness of extruded member 200. In certain
embodiments, extruded member 200 can be a single strand of material
formed into multiple layers. In certain embodiments, each layer can
comprise a single extruded member 200. In certain embodiments,
multiple extruded members 200 can make up a single layer. Each
layer can have the same or different pattern. In certain
embodiments, particular areas of sole 100 can include more layers
than others. For example, in certain embodiments, rearfoot area 130
can include one or more additional layers of extruded member 200.
Additional layers can be included in any part of sole 100.
[0073] FIG. 5 illustrates forefoot area 110, according to an
embodiment. FIG. 6 illustrates midfoot area 120, according to an
embodiment. As shown, for example, in FIGS. 5 and 6, the pattern
for extruded member 200 can be different along the length of sole
100, between each layer, and in certain key locations of sole 100.
For example, in certain embodiments, first layer 202 and third
layer 206 of extruded member 200 can have undulations 210 forming
loops 212 which can extend from medial side 140 to lateral side 150
of sole 100. In certain embodiments, second layer 204 of extruded
member 200 can extend in a generally lengthwise direction of sole
100. In certain embodiments, second layer 204 can be generally
perpendicular to first layer 202 and third layer 206, which can be
formed in a transverse direction of sole 100. In certain
embodiments, each of the layers can be formed at an angle with
respect to a lengthwise or a transverse direction of sole 100. In
certain embodiments, the pattern or direction of extruded member
200 can change along the length or width of sole 100. For example,
within a single layer, extruded member 200 can run in a lengthwise
direction in forefoot area 110, an angled direction in midfoot area
120, and a transverse direction in rearfoot area 130.
[0074] FIG. 7 illustrates a top view of rearfoot area 130,
according to an embodiment. As shown in FIG. 7, in certain
embodiments, rearfoot area 130 can include one or more additional
layers of extruded member 200. In certain embodiments, extruded
member 200 can be formed as coil 220. Other shapes and designs for
coil 220 are contemplated, for example, a spiral pattern to
accommodate a heel of the wearer.
[0075] FIG. 8 illustrates a bottom view of rearfoot area 130,
according to an embodiment. As shown in FIG. 8, bottom surface 170
of rearfoot area 130 can be formed with a different pattern than
top surface 160 illustrated in FIG. 7. In certain embodiments,
first layer 202 of extruded member 200 can include undulations 210
having loops 212, which can contact an adjacent loop 212 at one or
more contact point 214. In certain embodiments, adjacent loops 212
can contact each other along a majority of the length of each loop
212.
[0076] FIG. 9 illustrates a perspective view of rearfoot area 130,
according to an embodiment. In certain embodiments, extruded member
200 can include first layer 202, second layer 204, third layer 206,
and fourth layer 208. These layers can have the same or different
design patterns. In certain embodiments, loops 212 of first layer
202 can be offset from loops 212 of second layer 204. In other
embodiments, loops 212 of different layers can be directly on top
of each other.
[0077] With reference to FIGS. 10 and 11, for example, in certain
embodiments, sole 100 can include extruded member 200 having a
generally uniform pattern, in that the layers (e.g., layer 202 and
layer 204) of extruded member 200 forming sole 100 are
substantially directly on top of each other (see FIG. 11).
Undulations 210 can be spaced relatively equally apart or the
distance between undulations 210 can vary, with the amplitude
varying along forefoot area 110, midfoot area 120, and rearfoot
area 130. Loops 212A, 212B, 212C can be spaced so as not to contact
adjacent loops 212. Some loops 212 can be generally flat along
medial side 140 and lateral side 150, for example, loops 212A in
rearfoot area 130. Other loops 212B and 212C can be angled along
medial side 140 and lateral side 150, respectively. In one
embodiment, adjacent layers 202 and 204 can be disposed
progressively inward or outward on top of a lower layer such that
sole 100 has a tiered or terraced structure.
[0078] FIG. 12 illustrates a top view of sole 100, according to an
embodiment. FIG. 12 illustrates extruded member 200 formed in a
cross-hatch pattern. First layer 202 can be oriented in a first
direction extending from medial side 140 to lateral side 150.
Second layer 204 can be oriented in a second direction extending
from medial side 140 to lateral side 150. In one embodiment, the
cross-hatch pattern can form diamond-shaped gaps 222 and/or
triangular gaps 224 in sole 100. Gaps can also be formed as other
shapes (e.g., square, circle, etc.).
[0079] As shown in FIG. 30, in certain embodiments, the gaps can be
selectively filled with similar or different material than extruded
member 200 to form cells 250. For example, a foam material can fill
particular gaps created between portions of extruded member 200. In
certain embodiments, the same or different material can be extruded
to fill gaps. Pre-formed inserts can also be inserted to fill the
gaps. Cells 250 can be located in selected areas, for example, a
heel strike area or an area under the ball of the foot. This can
improve cushioning and shock absorption, and the overall weight of
the footwear. In some embodiments, cells 250 located along a
sidewall of the sole may be filled with a material to provide
increased stability. It is contemplated that gaps in any of the
embodiments described herein can be filled in a similar manner.
[0080] As shown in FIG. 12, first layer 202 and second layer 204
can be oriented at an angle with respect to the lengthwise
direction of sole 100. First layer 202 and second layer 204 can be
oriented at any angle, including parallel or perpendicular angles.
In certain embodiments, the "tightness" (i.e., size of the gaps) of
the cross-hatch can vary within a layer or between layers. The
angle can be changed along the length of sole 100 such that, for
example, the extruded member 200 runs at different angles in a
forefoot portion, midfoot portion, and/or rearfoot portion of sole
100.
[0081] In one embodiment, sole 100 may include one or more extruded
members 200 comprising a weave pattern. For example, a sole such as
the one in FIG. 12 can be created by "weaving" two or more extruded
members 200. To accomplish this, two or more extrusion nozzles can
be operated at the same time and coordinated such that the extruded
members 200 create a woven "over-under" pattern. In one embodiment,
one or more members of the weave pattern may be made of different
materials, which may provide improved cushioning and/or ride for
the wearer.
[0082] FIG. 13 illustrates a top view of sole 100, according to an
embodiment. FIG. 13 illustrates a pattern, which in certain
embodiments, can be formed by creating an outline of medial side
140 and lateral side 150 with extruded member 200 and then filling
in an interior area of sole 100. In certain embodiments, the
pattern can be formed with a continuous loop or spiral that starts
at an interior location of sole 100 and goes outward, or that
starts at an exterior location of sole 100 and goes inward. In
certain embodiments, in forefoot area 110, each ring of extruded
member 200 can contact an adjacent ring. In certain embodiments,
for example as shown in rearfoot area 130, gaps 222 can be formed
by spacing each ring of extruded member 200. In certain
embodiments, in rearfoot area 130, each ring of extruded member 200
can contact an adjacent ring. In certain embodiments, in forefoot
area 110, gaps 222 can be formed by spacing each ring of extruded
member 200.
[0083] In certain embodiments, other features of articles of
footwear can be incorporated into sole 100. For example, a bladder
can be inserted between layers of extruded member 200. In certain
embodiments, the bladder can be inserted between layers during the
extrusion process. With reference to FIGS. 14-17, in certain
embodiments, sole 100 can include intermediate sole 230. By way of
example, in certain embodiments, intermediate sole 230 can be a
bladder such as those disclosed in U.S. Pat. No. 5,771,606, which
is incorporated herein by reference thereto in its entirety. In
certain embodiments, intermediate sole 230 can be an inflatable
bladder. In certain embodiments, intermediate sole 230 can be a
rigid support member (e.g., plastic, metal, composite, etc.). In
certain embodiments, intermediate sole 230 can be a cushioning
material (e.g., foam, rubber, gel, etc.). In certain embodiments,
intermediate sole 230 can be a foam insert. In certain embodiments,
intermediate sole 230 can be a sealed or non-sealed container
embedded at least partially within sole 100. In certain
embodiments, intermediate sole 230 can be a temporary insert that
can inserted and removed. In certain embodiments, a temporary
insert can be used to form a void in sole 100. For example, the
temporary insert can be heated or melted so that it can be removed
from sole 100. For example, a temporary insert can be made of a
malleable material (e.g., wax), sole 100 can be extruded around the
temporary insert, and the temporary insert can be heated to remove
it from sole 100, creating a void.
[0084] In certain embodiments, one or more intermediate sole 230
can be located along top surface 160, bottom surface 170, and/or in
between layers of extruded member 200. Intermediate sole 230 can be
located along the entire length of sole 100, or at any area along
sole 100, for example, at rearfoot area 130, midfoot area 120,
and/or forefoot area 110. For example, intermediate sole 230 shown
in FIGS. 14-17 extends from rearfoot area 130, along midfoot area
120, and partially into forefoot area 110. In certain embodiments,
the shape of intermediate sole 230 can vary along its length. For
example, intermediate sole 230 can be wider in forefoot area 110
than in midfoot area 120. Intermediate sole 230 can extend entirely
or partially between medial side 140 and lateral side 150.
[0085] In certain embodiments, extruded member 200 can be formed to
at least partially cover intermediate sole 230. For example,
intermediate sole 230 can be located between top surface 160 and
bottom surface 170 of sole 100. In certain embodiments,
intermediate sole 230 can be "sandwiched" between top surface 160
and bottom surface 170.
[0086] In certain embodiments, extruded member 200 can have
undulations 210 with loops 212 such that intermediate sole 230 can
be at least partially visible between undulations 210. In certain
embodiments, extruded member 200 can entirely enclose intermediate
sole 230 between one or more layers.
[0087] As shown, for example, in FIG. 16, in certain embodiments,
intermediate sole 230 can be located between an outsole portion 232
and midsole portion 234 formed by one or more extruded members 200.
In certain embodiments, extruded member 200 can be formed to create
stepped region 236, which can have an increasing or decreasing
number of layers along its length and/or width. For example,
stepped region 236 can span midfoot area 120 and the number of
layers can progressively decrease from the portion of stepped
region 236 nearest rearfoot area 130 to forefoot area 110, as shown
in FIG. 16.
[0088] FIG. 17 illustrates a bottom view of sole 100, according to
an embodiment. In certain embodiments, extruded member 200 can be
formed to create bottom surface 170 of outsole portion 232. In
certain embodiments, outsole portion 232 can be located beneath
intermediate sole 230. Outsole portion 232 can be the same or
different material as midsole portion 234 shown in FIGS. 14-16.
Outsole portion 232 can have the same or different pattern as
midsole portion 234. In certain embodiments, outsole portion 232
can have different physical properties than midsole portion
234.
[0089] FIGS. 18-20 illustrate bladder 300, according to an
embodiment. In certain embodiments, bladder 300 can be incorporated
into an article of footwear. For example, in certain embodiments,
bladder 300 and extruded member 200 can form an upper or a portion
of an upper or a sole or a portion of a sole for an article of
footwear. In certain embodiments, bladder 300 can be an inflatable
bladder, and can be filled with a fluid medium.
[0090] FIG. 18 shows a front view and FIG. 19 shows a perspective
view of bladder 300. In certain embodiments, bladder 300 can
include central portion 301 and one or more side portions 303. In
certain embodiments, bladder 300 can include front side 302 and
back side 304 (see FIG. 20). In certain embodiments, bladder 300
can include pump 306 and/or release valve 308. In certain
embodiments, bladder 300 can have exterior layer 310 and interior
cavity 312. In certain embodiments, interior cavity 312 can be in
fluid connection with pump 306 and release valve 308, and
configured to contain a fluid medium (e.g., air).
[0091] In certain embodiments, one or more extruded members 200 can
be extruded onto exterior layer 310 of bladder 300. In certain
embodiments, an adhesive can be applied to exterior layer 310 of
bladder 300 prior to adding extruded member 200. In certain
embodiments, extruded member 200 can form one or more layers on
bladder 300. All or part of bladder 300 can be covered by extruded
member 200. In certain embodiments, extruded member 200 can follow
a contour or outline of bladder 300.
[0092] As shown, for example, on back side 304 in FIG. 20, in
certain embodiments, one or more extruded members 200 can be formed
on exterior layer 310 of central portion 301 and side portions 303.
In certain embodiments, extruded members 200 of central portion 301
and side portions 303 can have a different pattern. For example,
central portion 301 can have a cross-hatch pattern and side
portions 303 can have a perpendicular mesh pattern. In certain
embodiments, extruded member 200 can follow a shape of interior
cavity 312. In certain embodiments, fold lines 314 can be formed
between extruded members 200 to provide flexibility to bladder 300.
Other patterns such as those described herein can be applied to
bladder 300.
[0093] Other portions of bladder 300 can also be formed from
extruded member 200. For example, fitment bodies or covers such as
pump cover 306 and release valve body 308 can be formed from
extruded member 200. In one embodiment, bladder 300 itself can also
be formed from extruded member 200.
[0094] In certain embodiments, bladder 300 can be formed using the
methods and processes described herein. By way of one non-limiting
example, one or more extruded members 200 can be extruded in a
continuously contacting pattern to form a bottom layer. A separator
(e.g., Teflon paper) can be placed on the bottom layer or a portion
of the bottom layer. A release valve and pump can be attached to or
positioned on the separator. A top layer can be extruded over the
separator, which can prevent the top and bottom layers from bonding
adjacent to the separator. The top layer can be extruded over the
separator and onto the bottom layer to form intimate contact with
the bottom layer in desired areas. The separator can be removed
from the formed bladder 300 and a final extruded layer can be added
to fully seal the top and bottom layers together at the separator
removal slot opening junction.
[0095] FIG. 21 illustrates an article of footwear 10, according to
an embodiment. Article of footwear 10 can include upper 400 and
sole 100. In certain embodiments, sole 100 can be formed from
extruded member 200, such as described herein. In certain
embodiments, sole 100 can be extruded directly on to upper 400. In
certain embodiments, upper 400 can be made of a fabric, leather, or
synthetic material and extruded member 200 can be extruded directly
onto the material. Adhesive can be applied to the material before
applying extruded member 200. In certain embodiments, sole 100 can
be extruded and upper 400 can be attached thereto, for example by
stitching or adhesive. In certain embodiments, portions of both
sole 100 and upper 400 can be extruded.
[0096] Methods for manufacturing a sole, midsole, portion of a
sole, and article of footwear are also contemplated. In certain
embodiments, a method for manufacturing a sole for an article of
footwear can include extruding one or more elongated members in a
controlled geometric pattern, for example, but not limited to, any
of the patterns described herein. Extruding the sole can provide
advantages over and even eliminate the need for a mold, such as
currently used when injection molding soles for articles of
footwear. Alternatively, the processes described herein can be used
to create a container, vessel, or mold, using one or more extruded
members, that other extrusions or cast media can be added to.
[0097] The extrusion process can be automated and/or computerized.
Automation can provide assembly line production and computerization
can provide the ability to modify or customize the design. Robotic
mechanisms can be used to facilitate the process. In certain
embodiments, the extruder nozzle can be stationary and a surface or
other device can be moved in a controlled manner to form the
extruded article. In other embodiments, the surface can be
stationary and the extruder can move. In certain embodiments, both
the surface and extruder can move.
[0098] FIG. 22 illustrates a sole being extruded, according to an
embodiment. In certain embodiments, extruder 500 can form extruded
member 200 directly onto surface 502 (e.g., a holder, plate, table,
or conveyer belt). In certain embodiments, surface 502 can be a
heated or cooled surface. Heating surface 502 can facilitate
adhesion between extruded member 200 and, for example, a substrate
on surface 502. In certain embodiments, surface 502 can be heated
to correspond to the temperature of extruded member 200 as it exits
the extruder. Cooling surface 502 can accelerate the rate at which
extruded member 502 cools. In certain embodiments, surface 502 can
be a vacuum surface. The vacuum surface can hold a substrate or
other piece of material in place so that extruded member 200 can be
extruded onto it without the material moving. In certain
embodiments, a midsole can be directly extruded onto an insole or
outsole.
[0099] In certain embodiments, extruder 500 can move according to a
pattern while extruding extruded member 200 in order to form a
sole. In certain embodiments, surface 502 can move according to a
pattern while extruder 500 remains stationary. In certain
embodiments, both extruder 500 and surface 502 can move according
to a pattern while extruded member 200 is extruded to form the
sole. For example, FIG. 25 illustrates movement of an extruder 500
and surface 502 with six degrees of freedom. In certain
embodiments, both extruder 500 and surface 502 can move in each of
the x-, y-, and z-directions. In certain embodiments, both extruder
500 and surface 502 can rotate in each of these directions (i.e.,
allowing for roll, pitch, and yaw.)
[0100] FIG. 26 illustrates extruder system 800 having extruder 802.
In certain embodiments, extruder system 800 can include an
extrusion arm having an additional heating zone 804 with heating
bands 806. Heating bands 806 can maintain the viscosity of the
extruded material as it travels along heating zone 804. In certain
embodiments, additional heating zone 804 can be approximately 0.5
meters in length, although the length can be longer or shorter. In
certain embodiments, additional heating zone 804 can be telescopic,
allowing the length to be easily adjusted. By including additional
heating zone 804, more space can be provided for a surface to be
placed under extruder 802 so that the surface, extruder 802, or
both can move freely and safely away from other components of
extruder system 800.
[0101] FIG. 29 illustrates sole 100, according to an embodiment. In
certain embodiments, sole 100 can include one or more extruded
members 200. In certain embodiments, sole 100 can also or
alternatively include substrate 240. For example, substrate 240 can
be rubber or foam in the shape of a shoe sole or insert for a shoe.
As shown in FIG. 29, sole 100 can include rearfoot region 242 and
forefoot region 244. Regions 242 and 244 can be formed from
multiple extruded members 200 in a concentric pattern (e.g.,
concentric circles, ovals, or other shapes). In certain
embodiments, there can be space between each concentric extruded
member 200 such that each extruded member 200 may move relative to
another extruded member 200, which may result in improved
cushioning and/or ride for the wearer. In some embodiments,
adjacent concentric extruded members 200 may be formed of different
materials. In certain embodiments, concentric extruded members 200
can contact each other. Regions 242 and 244 can provide additional
cushioning and/or shock absorption at selected areas of sole 100,
for example, the heel and under the ball of the foot.
[0102] In certain embodiments, the method can include extruding one
or more elongated members to form a plurality of layers. In certain
embodiments, the method can include extruding a single, continuous
elongated member to form the sole.
[0103] The extrusion processes described herein can be combined
with other methods of manufacturing. For example, a portion of a
sole can be formed in a mold and combined with an extruded member.
In one embodiment, a thermoplastic cup sole can be extruded and
dispensed urethane foam can be added into the cup. In certain
embodiments, select portions of a sole can be extruded and then
filled with similar or different materials (e.g., dispensed
urethane foam). For example, a "skeleton structure" can be formed
using an extruded material (e.g., TPU) and filled with another
material (e.g., dispensed urethane foam).
[0104] Forming the sole by means of extrusion can allow for
complete customization of the sole by adjusting the pattern and
physical properties of the extruded member. FIG. 23 illustrates a
process for creating a customized sole, according to an embodiment.
FIG. 24 illustrates components of a system for manufacturing a
customized sole, according to an embodiment.
[0105] In certain embodiments, pressure data for an intended
wearer's foot can be obtained (step 600). For example, the intended
wearer can stand on a pressure sensor (e.g., sensor pad 700) to
determine the pressure distribution of the wearer's foot. In
certain embodiments, the pressure data can be delivered to and/or
analyzed by a computer 702 (steps 602, 604). The data can be
recorded by computer 702 (step 606). In certain embodiments,
software on computer 702 can generate a "heat map", which can be
presented on a visual display, indicating the relative pressure
exerted by each part of the foot (step 608). In certain
embodiments, computer 702 can analyze the pressure data to
determine an optimal sole design to properly support and cushion
each part of the intended wearer's foot (step 610).
[0106] In certain embodiments, the pressure data and/or design can
be sent to a local or remote computer (e.g., through direct
connection, wireless connection, or over the Internet) that can
control an extruder 704 (step 612). In this manner, an intended
wearer's foot pressure data can be obtained in a retail store and
the data can be sent to a manufacturing facility so that the
customized sole design can be extruded and incorporated into an
article of footwear. Upon receiving the design instructions,
extruder 704 can form one or more extruded members in a controlled
geometric pattern to create the sole based on the pressure data
(step 614). Other data, for example, foot size and shape can
similarly be collected, analyzed, and used to create the customized
sole. The data can be used separately or collectively.
[0107] Referring to FIGS. 23 and 24, a method of manufacturing a
sole for an article of footwear can include measuring data of a
foot using a sensor 700, sending the data to computer 702, which is
configured to control extruder 704, and extruding one or more
extruded members 200 in a controlled geometric pattern to form the
sole based on the data. In certain embodiments, the data can be
recorded in a memory of computer 702. In certain embodiments,
computer 702 can analyze the data. In certain embodiments a pattern
for the sole can be designed based on the data. In certain
embodiments, computer 702 can control extruder 704 to form a sole,
without first obtaining data. For example, computer 702 can
implement pre-programmed patterns for soles.
[0108] Other parts of articles of footwear and entire articles of
footwear can be made using one or more extruded members and the
methods, processes and/or components described herein. For example,
an upper or a portion of an upper can be formed from an extruded
member. In certain embodiments, one or more extruded members can be
extruded onto a piece of material (e.g., fabric or synthetic) to
form an upper or a portion of an upper. In certain embodiments, one
or more layers of textile material can be inserted over or between
one or more layers of an extruded member to form an upper. In
certain embodiments, an article of footwear including a sole and an
upper can be formed from one or more extruded members as a single,
unitary structure. By way of example, in certain embodiments, one
or more extruded members can be extruded onto fabric to form an
upper, a midsole, quarter panels, heel counter, etc., and the
fabric can be formed, cut, or sewn to form an article of
footwear.
[0109] In certain embodiments, extruded members can form other
parts of an article of footwear, for example, heel counters, lace
holders, etc. In certain embodiments, a last can be used, upon
which the extruded member can be formed. After the extruded
material cools, cures, or reacts, the last can be removed and the
extruded member can retain its shape forming the upper. In certain
embodiments, one or more extruded members can be extruded and
manually manipulated to form an upper or any other portion of an
article of footwear.
[0110] In certain embodiments, for example, as shown in FIG. 28,
extrusion can be combined with traditional lasting techniques.
Upper 830 can be placed on last 820. In certain embodiments, upper
830 and last 820 can be scanned by a computing device to define
spatial data so that the sole is accurately extruded onto upper
830. Extruder 802 can then extrude a sole onto upper 830 via
extruder nozzle 810. This process can be automated to increase
production speed, for example, in an assembly line manner.
[0111] In certain embodiments, patterns for uppers can include
flexible and non-flexible areas. In certain embodiments, patterns
can include stretchable and non-stretchable areas. In certain
embodiments, textile material can surround one or more extruded
members forming the upper. In certain embodiments, inserts (e.g.,
foam layers) can be included in portions of an upper.
[0112] Other articles of manufacture can be formed or include parts
formed according to the methods described herein. By way of
example, extruded members can be incorporated with other sporting
goods equipment, such as, but not limited to, pads (including, but
not limited to knee pads, elbow pads, shoulder pads, shin guards,
and chest protectors), helmets, gloves, sticks, skates, golf clubs,
grips, and balls. For example, an extruded member can be formed
directly onto protective padding to provide additional impact
absorption. In certain embodiments, concentric circles, spirals or
other features in these areas can provide protection or support. In
certain embodiments, the extruded member can be extruded onto a
substrate material (e.g., mesh) to improve adhesion of the extruded
member to the protective padding.
[0113] By way of further example, a chest protector incorporating
one or more extruded member 200 can be formed. In certain
embodiments, an extruded member 200 can be extruded onto a textile
or synthetic material that is in the shape of a chest protector.
The extruded member 200 can form the bulk of the protective
material. Certain areas of the extruded material 200 can be
thinner, for example to allow fastening elements to be attached to
the chest protector. An extruded member 200 can outline an area
that can be filled with another material (e.g., dispensed foam)
that can provide protection without significantly increasing
weight. It will be appreciated that in other embodiments the
substrate may include textiles or synthetic materials sized and
shaped for any desired product, including portions of a footwear
upper and apparel.
[0114] One or more extruded members can also be formed in a
controlled pattern to create apparel, including, but not limited
to, pants, shorts, shirts, jackets, hats, etc. In certain
embodiments, articles of apparel can be formed by extruding one or
more extruded members over, on, around, or in a shaped mold or
cast, for example. In certain embodiments, articles of apparel can
be formed in three-dimensional shapes. In certain embodiments,
after the extruded material is ready (e.g., after it cools, cures,
reacts, etc., as necessary) the extruded member or members can be
removed, retaining its shape as the article of apparel.
[0115] In certain embodiments, inserts (e.g., textiles, foams,
plastics, etc.) can be included in the articles of apparel.
Articles of apparel can include areas of extruded material to
provide cushioning or padding. In certain embodiments, elbow, knee,
or other areas of apparel can include extruded material. For
example, concentric circles or spirals in these areas can provide
protection or support. Extruded material can also be added to
apparel for aesthetic or fashion purposes. For example, extruded
accents, piping, or designs can be added to apparel.
[0116] While various embodiments have been described herein, they
have been presented by way of example only, and not limitation. It
should be apparent that adaptations and modifications are intended
to be within the meaning and range of equivalents of the disclosed
embodiments, based on the teaching and guidance presented herein.
It therefore will be apparent to one skilled in the art that
various changes in form and detail can be made to the embodiments
disclosed herein without departing from the spirit and scope of the
present disclosure. The elements of the embodiments presented
herein are not necessarily mutually exclusive, but may be
interchanged to meet various needs as would be appreciated by one
of skill in the art.
[0117] It is to be understood that the phraseology or terminology
used herein is for the purpose of description and not of
limitation. The breadth and scope of the present disclosure should
not be limited by any of the above-described exemplary embodiments,
but should be defined only in accordance with the following claims
and their equivalents.
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